aquaculture scoop april 2015 -

Aquaculture Scoop is a magazine for aquaculture professionals worldwide

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COOLING FISH FEEDGraintec A/SRead more on page 12

Profitable Aquafeed Moisture Control:Moisture control of Aquafeed exiting a dryeris costing manufacturers p.18

Fish Health App p.6 Extruder Control p.5

Issue 08 / April 2015

Extruder Control Tovalia - iScan IM system

Moisture ManagementControlling moisture content

Fish Health App Fish Disease Diagnostics Ltd

Cooling Cooling fish feed

Expo list Top events related to aquaculture from around the world, on p. 22

GLOBAL EVENTS:We list the world’s top industry events. PAGE 22

18

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Seafood now provides more than half of the

world's protein.

Welcome to the April issue

Welcome to the latest issue of Aquaculture Scoop.

In this issue we take a look at Extruder Control in Aquaculture Feed production. We learn about Moisture Management courtesy of Tovalia and A new Fish Health digital App that has the potential to make quick diagnosis an easily accessible online service. We also look at interesting and extensive information on cooling of fish feed.

With many events coming up why not visit our website and download the latest 2015 wall planner.

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Aquaculture Scoop April 2015 Page 03

Extruder Control Tovalia - iScan IM system

Fish Health App Fish Disease Diagnostics Ltd

Moisture ManagementControlling moisture content

Cooling Cooling fish feed

Editor’s Comment

Drying TechnologyProfitable moisture control

www.aquariuslawyers.com.au

mailto:[email protected]

System for extruder control

Tovalia sarl in France is committed to develop new tools for optimization and improvement of the pellet production.

This new product, iScan IM is a tool for the operator to control his extruder to best efficiency. Buoyancy is very important for fish feed pellets. They need to sink at the correct speed. The iScan IM measures the exact density of each pellet, not bulk density. As well as monitoring the exact pellet density, the iScan IM also monitors the exact pellet size. If the size of pellet starts to change it is usually a sign that the extruder needs to be cleaned or pressure


Extruder control More information:

Olafur Jonsson TovaliaParc d’activité de Sacuny 108, Rue Barthélémy Thimonnier 69530 BrignaisFranceWeb: www.tovalia.com

• Online and continuous measurements of the pellet size to monitor the performance of the extruder. In case it needs more pressure, steam or cleaning

• Online and continuous shininess measurement to determine oil absorption of pellets

For further information please contact Olafur Jonsson at [email protected]

in the extruder is insufficient. The iScan IM system. Online analysis of pellets. Continuous measurement of density, size and colour.

The new system uses an online digital image processing of pellets for size and colour of pellets as well as a flow scale for weighing.

The benefits of the new system are: • Online and continuous exact density measurement of individual pellets (not bulk density) - to control sinking properties

iScan IM is a tool for the operator to control his extruder to best efficiency


Fish health

Fish Disease Diagnostics Ltd have just completed the latest version. This latest version, currently in English, and formatted to work on PC’s and Mac’s and will progressively be modified to work optimally on all mobile platforms, Tablets etc.

Over the next year or so, Fish Disease Diagnostics Ltd will begin serious technical translations into all the important languages in which fish culture is important, e.g. Chinese, Japanese, Spanish etc.

The latest version, FV v 3.0 has some 132 topics, and includes contributions from some 40 Fish Pathologists of renown, from 14 countries. It has many more symptoms for diagnosis, all of which are illustrated with colour photos, many with several photos of each to assist in diagnosis. There are now 508 symptoms as follows:-

Behaviour 41 symptoms, Body 67 symptoms, Eyes 15 symptoms, Fins 32, symptoms, Gills 22 symptoms, Skin 45 symptoms, Water quality indications 27, Haematology symptoms 16, Histology 106 symptoms, and Pathology 137 symptoms.

With a total of around 1500 colour photos to aid diagnosis, as well as around 125 videos, which include some lectures on important topics by Professors who are experts in their field.

There are 2 versions, of the latest edition viz.…..

A Hobby version aimed at the 700 million Aquarium owners world wide, who for cost reasons could not really justify the cost of previous versions, and will be offered the use of the APP for a 48 hour usage for only £5.00 (or it’s equivalent in their own countries i.e $7.50 in the USA.)

A Professional or PRO version which can be subscribed to for £10.00 for a similar time usage, or one can take a year’s subscription for £300.00 ($450).

The PRO version has comprehensive sections, which deal with Pathology, Histology, Haemotology, and Bacteriology. For legal and other reasons these are not included in the Hobby version. The users will NOT actually buy the programme, in the old way, but receive a key to interact at any time for their chosen period with the web site.

By using the Fish Disease Diagnostics Ltd website all users will have access to constant and ongoing updates. This is important as new diseases and treatments are always emerging. In 6-8 months a Shellfish section will created and added as this is today an important part of the Aquaculture scene.

Why not try using the Professional version for the price of £10, as indicated on our web site (www.fishvetapp.com) and if you decide to subscribe for the year, this usage cost will be deducted.

For more information visit:

www.fishvetapp.com

Latest software viz. Fish-Vet v.2.0 available now!


Moisture Measurement

When producing fish feed, controlling the moisture content is one of the most important control parameter.

Moisture content will affect the quality of the finished feed and its shelf life. Quality of fish feed pellets is very important to have the desired buoyancy. Moisture content in the feed will also directly affect the profitability of the feed mill.

It is therefore evident that this parameter should be monitored and controlled to an optimum level at each stage in the process.

Moisture Measuring Techniques

Measuring moisture content can be done by the so-called moisture balance method; this method involves heating a certain amount of material and the weight loss is interpreted as moisture. This method takes from 25 - 35 minutes and is not very practical if the operator wants to react quickly to changes in the production.

Measuring moisture in fish feed pellets instantly and continuously is however tricky. The three most common technologies for doing these measurements are:

1. Measuring the response of Near Infrared (NIR) Light as it is reflected off the material

More information:

Olafur Jonsson TovaliaParc d’activité de Sacuny 108, Rue Barthélémy Thimonnier 69530 BrignaisFranceWeb: www.tovalia.com

Moisture measurement systems in fish feed pellets

2. Measuring the dielectric properties of the material with Electrical Capacitance

3. Measuring the dielectric properties of the material with Microwave

The advantage of NIR is that it can measure more than just the moisture content. It can measure protein and fat. However, the NIR requires a separate calibration for each new recipe, which is not ideal for compound feed, where recipes constantly change. For pellets the NIR technology has the disadvantage that it is a surface measurement, it will not measure the moisture inside the pellet.

Electrical capacitance is measured at low frequency. This is the cheapest method. However at this frequency, the ionic conduction effects are considerable. The effects of density as well as temperature are also considerable.

1. 2.

3.

www.aquarama.com.sg

[email protected]



The Microwave method for online moisture measurements of fish feed pellets is becoming the recognized method in the industry. At microwave frequencies above 2-3GHz, the ionic conduction effects are negligible. The measurements of dielectric properties resulting from dipolar orientational polarisation of the water molecules inside the material are directly correlated with moisture content. However, microwaves will be affected by temperature as well as density of the material.

There are several sensor technologies or sensor types that can be used with microwave technology to measure online moisture content in the feed pellets, but the most common sensor type is the planar sensor, or cavity resonator. This is a cylindrical cup placed on the outside of a silo or chute.

The installation is fairly easy. This sensor can be mounted on a hopper or a chute.

The disadvantages of this design is that the measurement area is unknown. The radiation of microwaves into the material is not defined, but rather depends on the material and the density of it. Therefore this method has 3 unknowns:

1. The moisture content,2. The density and3. The size of the area being measured.

It is often estimated that the measurement area is a few square centimeters. These sensors need to be cleaned regularly in case there is a dirt settlement on the sensor surface, as the dirt will influence the moisture measurement of the material, because the proportion of the dirt will be significant to the total measurement area.

A New Solution in Moisture Sensing Devices

There is a new design of microwave moisture sensors on the market now that uses planar antennas. There are two plates separated by a specific distance. A Transmitter is in one plate and a receiver in another. This device is mounted on a silo or a hopper and the product passes between these two specifically designed plates as it is sensed for moisture content. This means the measurement area is known.

The amount of material measured is a cross section of the volume of material between the two plates, which is considerably more than what current planar sensors do. Effects of dust, dirt or buildup on the sensor are therefore negligible.

As with the planar sensors, this new design is installed in a hopper or a chute. The requirement for this sensor to work well is that the two sensor plates need to be fully covered with material.

Tested and Proven

This new design has been thoroughly tested in feed mills. Typical accuracies of 0.4% were achieved during development and evaluation of these sensors.

Aquaculture Scoop April 2015


Graph 1. Comparison of moisture content by Tovalia sensor and the moisture balance method. In total 71 samples were analysed from 39 different recipes. The Tovalia sensor used a single calibration for all measurements.

Fore more information contact Olafur Jonsson or Hennie Pieterse at [email protected] or [email protected]

AquaDirectFree news for the industry

Visit our blog for updates, industry news and more:

http://aquaculturedirect.blogspot.co.uk/


Cooling

Cooling

22.A GENERAL

Cooling of pet food and fish feed is a process of removing heat from the prod-uct and in some cases also moisture will be removed from the product.

Cooling is required in order to:

• Minimize bacteria growth • Avoid condensation of product in bins and/or bags• Increase storage time • Increase hardness (better durability)• In high oil diets eliminate risk for oil leakage

The cooler performance can be illustrated as follows: (see diagram right)

Cooling should also be a gradual process. If the product (pellets or kibbles) are cooled too quickly, cracks in the outer surface of the product are created which as a consequence can lead to higher abrasion.

More information:

GRAINTEC A/S40 EnghavevejDK-7100 Vejle DenmarkTel: +45 76 436910Web: www.graintec.com

If the heat is not removed from the centre of the product heat will start to transfer to the surface during storing leading to risk of condensation inside bins and bags. (Ref. sketches and tables below)

When (hot) product filled into bags is moved from a hot process building to a cold warehouse condensation of water will occur inside the bags. Water in bags will lead to bacteria growth and moulds.


Cooling

The table below can be used to evaluate if risk of condensation exists.

Example: Product temperature is 30˚C and RH in bags is 70%. Surface of bag will obtain warehouse room temperature over time and lead to condensation in the bags as dew point temperature is 23.9˚C.

22.B RETENTION/COOLING TIME

The table below shows the recommended retention/cooling time for fish feed pellets with different pellet size and fat/oil content. As can be seen from the table the higher the fat/oil content the higher retention time is required to remove the heat from the centre of the pellet. The lines represent fat/oil content of 10, 20, 30 and 40%.

It should be noted from the table below that small pellets emit the heat more quickly than large pellets. (Source Graintec)

Dew point temperature 23.9˚C. (Ref. example above)


Cooling

22.C. COOLER TYPES

In practise two types of coolers are the most commonly used: Horizontal belt coolers or counter flow coolers. Other types of coolers exist such as fluid bed coolers and a combination of cross and counter flow coolers but not widely used in fish feed and pet food production.

The table bellows describes the difference between the two most common types of coolers: The horizontal belt cooler and the counter flow cooler.

Horizontal cooler(Belt cooler)

Counter flow cooler(Bunker cooler)

Referencephoto

Floor space

Cooling airrequirement

Height of product in cooler

Requires extra floor space

High

10 - 40 cm bed depth on trays (Ref below)

Requires less floor space

Low

60 - 150cm

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Cooling

Horizontal cooler(Belt cooler)

Counter flow cooler(Bunker cooler)

Principle of air flow

Product bed

Cross flow Counter flow

Bed trays with holes. Holes to be selected according to product sizes. Different bed trays with different hole pattern exist.

Geelen swivel valve. Air gab between valves can be adjusted according to product size. Different types of gates exist.

Air velocity (depends on product – ref table below)

0.3 - 0.6 m/sec (higher air velocity may lead to formation of air holes in the product bed)

0.4 – 1.5 m/sec (depending on product size)

Cooling efficiency

Hygiene

Fragile big products

High fat products

Small products

Capital investment

Inferior

Inferior

Superior

High

Horizontal cooler (Belt cooler)

Inferior

Inferior

Superior

Superior

Inferior

Superior

Superior

Counter flow cooler (Bunker cooler)

Low

Operating costs (energyconsumption and maintenance)

High Low

Aquaculture Directory


Cooling

22.D. AIR SPEED, TEMPERATURE AND VOLUME

Graintec has developed a computation programme for calculating the required air volume requirement to cool a specific product (pellet) in a counter flow cooler. The programme will also calculate moisture removal from the product during cooling if applicable (low fat products). The table below can be used as a guideline for selecting the air speed in a counter flow cooler. It is to be noted that the cooler manufacturer should be consulted as different cooler types/design will have an impact on the air speed.

Note: To regulate the air speed through the product air flow control is always required. Air flow control can be done by use of a frequency control fan motor, air regulation valve or similar control valve.

Cooling air temperature is in many cases ambient air temperature around the cooler inlet. As a consequence the pellet temperature exit the cooler can by using ambient air temperature only obtain ambient temperature plus 3 - 5˚C. In some applications this may not be sufficient cooling of pellets to avoid condensation in the bags and in case of high oil/fat product oil leakage from the product will occur.

It is therefore necessary to use chilled air for cooling purposes. A flow diagram of a typical installation is shown to the right.

Flow diagram right:Cold air (5 - 15˚C) to the cooler is produced by a liquid chiller. The liquid cooling water is pumped to a water/air heat exchanger that cools the air temperature to desired temperature.

This type of installation is used in many salmon/trout fish feed factories producing high oil/fat products.

!

Table above:To high air speed will lift the product out of the cooler (into ducts, cyclone and air fan). The recommended air speeds indicated in the table will eliminate the risk of product being lifted out of the cooler. When air speed are to low so be the heat removal and the possibility of moisture removal is high.


Cooling

As mentioned above Graintec has developed a computation programme that can calculate the required air volume and temperature to cool the product to the desired temperature that is always above cooling air temperature.

The table below is based on a computation of product size ø 6.0 mm with a length of 6.0 mm. The cooling air temperature is 15˚C and the product enters into the cooler with a temperature of 50˚C and exits at 20˚C.

The required air volume is calculated with the assumption that the cooling air exhaust leaving the cooler should be 45˚C. Fat/oil levels are shown to the left and the pellet water content is 10%.

OIL CONTENT CAPACITY KG/H

In percent 5,000 kg/h 10,000 kg/h 15,000 kg/h 20,000 kg/h

7,600 m³/h

7,900 m³/h

8,250 m³/h

8,600 m³/h

10%

20%

30%

40%

15,100 m³/h

15,800 m³/h

16,500 m³/h

17,200 m³/h

22,700 m³/h

23,800 m³/h

24,800 m³/h

25,800 m³/h

30,400 m³/h

31,600 m³/h

33,000 m³/h

34,400 m³/h


Drying Technology

Explanation of Exclusive Solutions:

A. Inside-the-Dryer MC Sensor:

An inside-the-dryer MC sensor significantly reduces dead time (time it takes for a disturbance entering the dryer to be detected). Since dead time and MC variation are directly proportional, a reduction in dead time reduces the MC variation proportionally.

This is illustrated by figure (1) that shows the effect of MC sensor location on the dead time and thus MC variation.

For example, if an inline MC sensor is located at the dryer exit, the dead time would be equal to the total drying time, for this example, 20 minutes. If the Delta T inside-the-dryer MC sensor is located

Moisture Sensing & Control Problems:

Moisture control of Aquafeed exiting a dryer is costing manufacturers significantly in terms of reduced production, higher unit energy costs, and lower quality from over and under-dried product. These losses are caused primarily by three main problems with currently-used, moisture (MC) sensing and control systems: (1) Lack of timely, and accurate MC data upon which to make a control decision; (2) Lack of simple, inexpensive, and non-problematic feed forward signals for evaporative load to the dryer; and (3) Lack of a precise mathematical method for re-calculating the process variable set point needed to maintain the target MC following evaporative load changes entering the dryer.

Moisture Sensing & Control Solution:

Fortunately, these three problems were solved by the mathematical derivation of the general dryer model:

MC = K1(∆T)p – (K2/Sq) (1)

This Delta T model relates the moisture (MC) of Aquafeed exiting a dryer to: (1) the temperature drop (∆T) of hot air following

contact with the wet product; and (2) the evaporative load to the dryer or the dryer speed (S). This model invented three solutions for the above-mentioned problems: (1) An “inside-the-dryer” MC softsensor consisting of two temperature sensors and software that is rugged, reliable, does not drift, and does not require re-calibration. (2) A simple, rugged, reliable, and relatively inexpensive evaporative load softsensor; and (3) A precise mathematical method for re-calculating a new ∆T setpoint needed to maintain the target MC following evaporative load changes to the dryer. When these three exclusive solutions are included in the patented Delta T MC Sensing and Control System, the target MC is maintained with at least 30% less MC variation than that achieved using currently-used Dryer MC Control systems.

More information:

John RobinsonOwner/PresidentDrying Technology, IncUSATel: +1 409 385 6422Email: [email protected]: www.moisturecontrols.com

Profitable Aquafeed Moisture Control

Figure (1) – Effect of MC Sensor Location on Dead Time


Drying Technology

14 minutes into the dryer, it would reduce the dead time for currently used control by 30%. If MC samples are used as the basis for control, the dead time would be much higher.

B. Inside-the-Dryer Evaporative Load Soft sensor:

Use of a feed forward evaporative load signal to improve traditional PID feedback control has been suggested. It would require an inline, MC sensor and a weigh belt on the wet feed to the dryer to calculate the evaporative load; however, inline, MC sensors are problematic for sensing wet feed to a dryer, and weigh belts are expensive. Consequently, this is not recommended for an Aquafeed drying operation. The Delta T inside-the-dryer evaporative load softsensor is simple, relatively inexpensive, and highly effective in supplying a feedforward signal for a dryer operation without adding additional problematic equipment.

C. Re-Calculation of the ∆T Setpoint:

The Delta T MC softsensor predict MC by continuously sensing the ∆T process variable inside a belt or fluid-bed dryer by measuring the temperature drop (∆T) in hot air following contact with the wet

product (see figure 2).

Due to the theoretical basis for the model, there is an extremely high correlation between MC and ∆T. Initially, the dryer is started up and a ∆T setpoint value is established for a given production rate that maintains the target MC. If the production rate or entering MC changes (change in evaporative load), a new is calculated that maintains the target MC at the new evaporative load. One dryer manufacturer offers a control system using the average of the two temperatures used in the delta calculation. The correlation between this average temperature method and MC is extremely low due to its non-theoretical basis. Additionally, there is no method for re-calculating a new setpoint following evaporative load changes.

For dryer-types such as rotary, flash, and spray, the exhaust temperature is sometimes used as the process variable setpoint; however, as soon as the evaporative load is changed, the setpoint needs to be re-calculated and there is no method for doing so due to the lack of a theoretical basis for this type control. As a result, correlation is very poor between exhaust temperature and product MC.

Figure (2) – Depiction of a Delta T MC Sensor

Economics of Delta T System:

Figure (3) compares the Delta T with currently used control methods. It illustrates how the exclusive benefits of the Delta T narrows the MC distribution curve such that when the upper 3 standard deviation (s.d.) points of each curve are superimposed over the upper specification limit (USL), there is an increase in the mean MC for the Delta T curve.

The difference in the mean MCs represent the total economic advantage in terms of: (1) increased production by leaving more water in the product (0.5% to 1.0%); (2) savings in unit energy costs (5%) by not having to evaporate that water left in the product plus additional energy savings from a cooler exhaust; and (3) improved product quality by controlling to the target with at least 30% less MC variation.

Setting the Target MC:

The Delta T normally reduces the product MC variation exiting a dryer by at least 30%. Equation (2) below illustrates the effect of reducing the MC variation (standard deviation = s.d.). Note that these calculations use 3.0 standard

Figure (3) – Illustrates Economic Benefit of Delta T Control


Drying Technology

deviations. If the specifications allow, 2.5 or 2 standard deviations may be used which will allow more water to be left in the product.

Old Target MC = [USL – (3) (old s.d.)] (2)

New Target MC = [USL – (1.0 - 0.30) (old s.d.)] (3)

By subtracting the New Target MC equation (3) from the Old Target MC equation (2), an estimate of the increase in mean MC, when s.d. = 3, and the reduction in s.d. is 30%, is equal to 0.9 (old s.d.).

Economic gain is derived from increasing the target MC without exceeding the USL, which leaves more water in the product; therefore, in order to increase the target MC, the s.d. must be decreased. For example, if the s.d. of an Aquafeed exiting the dryer is 0.50, the Delta T should be able to increase the mean MC by (0.50 x 0.90) = 0.45%. If the product-selling price is $800 per ton, the savings for a plant producing 100,000 tons/yr would be $344,000, or $3.44 per ton. Simple payback of investment ranges from 3 to 6 months.

Ease of Operation:

The Delta T is relatively easy to startup and operate. Once started, it handles varying evaporative loads to the dryer caused by changes in production rate or changes in MC of feed to dryer. It can be packaged in the following manner:

(1) A stand-alone system consisting of a 24” x 24” panel box with the necessary I/O model, plus an industrialized PC touch screen on the panel box door. Two ordinary temperature sensors (T/c or RTD) input signals and an output signal for adjusting heat to the dryer used. (See figure (4)

(2) If a PLC is available, it can be linked to the PLC and a Desktop PC in control room or the panel box with industrialized PC

Figure (4) – Delta T Dryer MC Sensing & Control System

without the I/O modules inside the box.

Summary and Conclusions:

The Delta T has been applied to Aquafeed, and related products such as Petfood, Animal Feed, and many other products. It has consistently reduced the MC s.d. at least 30%. As a result, the mean MC has been significantly reduced, thus allowing 0.50 to 1.0% more water to be safely left in the product without exceeding existing specifications; 4% to 7% less unit thermal energy consumed, and product quality has been improved by the elimination of over and under-dried product. The success of the Delta T is attributed to a

theoretically-based general, MC control model that solved the three main problems with currently-used MC sensing and control by producing exclusive features such as: (1) an inside-the dryer MC softsensor; (2) an inside-the-dryer evaporative load softsensor; (3) the capability for re-calculating the setpoint to maintain the target MC; (4), a rugged, reliable, operator-friendly control system; and (5) an extremely low return on investment of 3 – 6 months.

www.�aap.com

www.victam.com

www.grapas.eu

mailto:[email protected]


Expo List

April

Seafood Expo Global21st-23rd AprilBelgium www.seafoodexpo.com

May

IAI Expo 3rd-5th May India www.iaiexpo.com

World Aquaculture 201526th-30thMay Korea www.was.org

Aquarama 201528th-31st May Singapore www.aquarama.com.sg

June

Victam International 20159th-11th June Germanywww.victam.com

July

The International Conference on Aquaculture & Fisheries20th-22nd JulyAustraliawww.aquaculture-fisheries.conferenceseries.com

August

Aqua Nor 18th – 21st August Norway www.nor-fishing.no

Events in detail

January

Innovations in feeding technologies and commercial fish farming27th January Russiawww.expohleb.breadbusiness.ru/eng

IPPE 27th-29th January USA www.ippexpo.com

February

Global Forum for Innovations in Agriculture3rd-5th February UAEwww.innovationsinagriculture.com

Aquaculture America 201519th-22nd February USA www.marevent.com

Aqua Aquaria India 20th-22nd FebruaryIndiawww.aquaaquaria.com

March

VIV Asia 11th-13th March Thailand www.vivasia.nl

Seafood Expo North America15th-17th March USA www.seafoodexpo.com

AquaMe16th-18th March United Arab Emirateswww.agramiddleeast.com/en/Aqua/Home

September

Seafood Expo Asia 2nd-4th September Hong Kongwww.seafoodexpo.com

World Seafood Congress 20155th -10th September UK www.wsc2015.com

October

AQUACULTURE EUROPE 201520th-23rd October Netherlands www.marevent.com

Submit your event to

[email protected] to see it featured

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